Expansion vessels

Reflex, Refix
Expansion vessels

Pressure maintenance

Pressure maintenance system tasks

Correct pressure ratios are a basic precondition for correct Essentially, pressure maintenance systems have to fulfil three
functioning of heating, solar and cooling water systems and fundamental tasks:
pressure booster systems. Like all other substances, the volume
1. Maintain the pressure within permissible limits at all points
of water changes with its temperature. Unlike other liquids, water
in the facility system. This means ensuring the permissible
does not expand proportionately to the temperature. As water
operating pressure is not exceeded but also maintaining a
cannot be compressed, this means the pressure increases
minimum pressure to avoid negative pressures, cavitation
significantly in closed systems as the temperature changes.
and evaporation.
Optimum pressure maintenance is achieved with two different 2. Compensating fluctuations in the volume of the facility water
pressure maintenance systems depending on the application: as a result of fluctuations in temperature.
Z
Static pressure maintenance systems (expansion vessels) 3. Balancing systemic water losses using a water reservoir.
Z
Dynamic pressure maintenance systems
Further information can be found in the brochure: Pressurisation Systems

Water uptake volume of a pressure expansion vessel Expansion volume flow and point of zero pressure
Pressure maintenance is required to compensate fluctuations A balancing volume flow must be transported via the
in volume between the maximum and the minimum system expansion line between the system and pressure
temperature and thus to maintain the pressure within a maintenance such that the calculated pressures for the
permissible range. To achieve this, there must be a sufficient pressure maintenance are produced correctly at the
water uptake volume which must correspond to the expan- point of zero pressure.
sion volume Ve and the water reservoir Vv. If devices are
In closed heating, solar and cooling systems, it is assumed
installed which extract and feed back a volume of water VD
that the expansion volume flow !e is the largest possible
from the system during operation, such as a vacuum
balancing volume flow. It occurs when the thermal output
degasser, this must also be taken into consideration. This
" G of heating or cooling sources is switched on or off.
also applies to volumes of steam VS which occur during
downtimes in solar collectors. If the temperature of the
medium drops below 0 °C or exceeds 70 °C at the connection
point of the pressure maintenance in the facility system, an
auxiliary vessel is to be installed in order to protect the
Thermal output "G
bladder of the expansion vessel.
Point of zero pressure

t
Water uptake volume Water uptake volume

VD water volume to be balanced, VD water volume to be balanced,

e. [Link] vacuum degassers e. [Link] vacuum degassers
VS volume of steam occurring Expansion VS volume of steam occurring
during solar system downtime volume !e during solar system downtime
V0 Ve expansion volume V0 Ve expansion volume
Expansion
volume VDi
VV water reservoir VV water reservoir

Z
in heating systems proportion of Ve for t > 70 °C
Z
in cooling systems proportion of Ve for t < 0 °C

6
 Pressure maintenance

Static pressure maintenance systems

Expansion vessels work as expansion or buffer vessels without Buffer and control vessels have to provide an intermediate
electricity, a compressor or pump. Expansion vessels have to storage for the difference between the requested and the required
balance the volume fluctuations between the greatest and the volume flow. If the requirement is to reduce the switching
lowest temperature. Product in the Reflex portfolio are used as frequency of the feed device, this is also known as a control vessel.
expansion vessels in heating, solar and cooling water systems In principle, the Refix product range is used as a buffer vessel in a
and products in the Refix portfolio are used to save potable water pressure booster system while the Reflex range is used as a
in hot water heating systems. control vessel in pump-driven pressure maintenance stations.

Reflex for closed heating, Refix for potable and

solar and cooling water process water systems as
systems well as special applications

Installation and function

Nitrogen filler valve
Reflex in a heating Refix in a pressure booster
system (example) system (example)
Gas chamber pad

Membrane ΔV = V₁ − V₂

Water chamber
Pressure booster system
Water uptake Water release
V₂ V₁
Facility system Consumer unit

The pressure pad supports the water column in the system and is pressure, the pump switches on and feeds the water.
adjusted accordingly before the vessel is filled with a volume of If the consumer units remove a lesser amount, the difference is
water. As the system is heated, the pressure increases resulting in temporarily stored in the buffer tank until the pressure pad is
the expanding water flowing from the facility system to the water compressed to the cut-out pressure and the pressure booster
chamber. The pressure pad in the gas chamber is compressed and system switches off. The resulting pressure drop leads to a
the pressure increases. As the system cools, the volume decreas- reduction in volume. If the consumer units draw water, temporari-
es and the pressure drops: the expansion water flows out of the ly stored water is extracted from the buffer tank until the cut-in
water chamber back into the facility system. The pressure pad in pressure occurs at the pressure pad and the pressure booster
the gas changer is adjusted to just under the cut-in pressure of system is switched on again.
the feed device. When the pressure drops below the cut-in

7
 Selection and calculation

Selection and calculation

Pressures in the system
Valid for supply pressure maintenance in heating, cooling and solar thermal systems

Excess pressures psv

pst = static pressure
p0 = minimum operating pressure pe ≤ pSV − 0.5 bar (for pSV ≤ 5.0 bar)
pa = supply pressure pe ≤ pSV × 0.9 (for pSV > 5.0 bar)
pe = final pressure Idle pressure range =
psv = safety valve actuating pressure pressure maintenance
target value
pa ≥ p0 + 0.3 bar
pa pe

Safety valve actuating pressure

p0
psv p0 ≥ pst + pD + 0.2 bar
pst
pst
bar/Ü
pressure (min. 1 bar)
Minimum operating

System pressure
Supply pressure
Static pressure

Final pressure
tv
psv
tR

pe

pF
pa
p0
VV V V + VE

Calculation values
Pressures are given as excess pressures and relate
to the connecting pieces for the expansion vessel
up to the highest point in the system.

Reflex recommendations
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Set the safety valve operating pressure sufficiently high:
pSV ≥ p0 + 1.5 bar
Z
If possible, when calculating the inlet gas pressure, select an extra 0.2 bar:
p0 ≥ H [m] + 0.2 bar
10
Z
Select an supply pressure of at least 1 bar on account of the necessary supply pressure
for the flow-through pumps—even for rooftop infrastructure centres: p0 ≥ 1 bar
Z
Set the fill or supply pressure on the water side in vented systems in cold
condition at least 0.3 bar above the supply pressure to ensure a water
reservoir inthe expansion vessel (VV = 0.005 × VA at least 3 l for
Vn > 15 l minimum volume indication according to the standard): pF ≥ p0 + 0.3 bar

21
Reflex

Quick selection table for expansion vessels

Heating Systems: 70/50 °C

Safety Valve pSV [bar] 2.5 3.0 4.0

Inlet Pressure p0 [bar] 0.5 1.0 1.5 0.5 1.0 1.5 1.8 1.5 2.0 2.5 3.0

Vn [litres] Contents VA [litres]

8 107 48 – 133 82 31 – 87 48 8 –
12 161 71 – 199 122 46 – 131 71 12 –
18 268 134 – 325 210 96 27 223 134 45 –
25 424 238 52 504 344 185 89 362 238 114 –
35 639 387 126 730 536 313 179 561 387 213 –
50 912 608 238 1,043 782 504 313 811 608 362 114
80 1,460 973 461 1,668 1,251 834 580 1,298 973 649 263
100 1,825 1,217 608 2,086 1,564 1,043 730 1,622 1,217 811 362
140 2,555 1,703 852 2,920 2,190 1,460 1,022 2,271 1,703 1,135 561
200 3,650 2,433 1,217 4,171 3,128 2,086 1,460 3,244 2,433 1,622 811
250 4,562 3,041 1,521 5,214 3,910 2,607 1,825 4,055 3,041 2,028 1,014
300 5,474 3,650 1,825 6,257 4,692 3,128 2,190 4,866 3,650 2,433 1,217
400 7,299 4,866 2,433 8,342 6,257 4,171 2,920 6,488 4,866 3,244 1,622
500 9,124 6,083 3,041 10,428 7,821 5,214 3,650 8,110 6,083 4,055 2,028
600 10,949 7,299 3,650 12,513 9,385 6,257 4,380 9,732 7,299 4,866 2,433
Reflex

800 14,599 9,732 4,866 16,684 12,513 8,342 5,839 12,976 9,732 6,488 3,244
1,000 18,248 12,165 6,083 20,855 15,641 10,428 7,299 16,221 12,165 8,110 4,055

Customised planning with

our configuration software

Reflex Solutions Pro

[Link]/en

Key data Calculation Result

Safety valve pSV = 3 bar
Water content (approximately) From the table
Static height Hst = 13 m
Radiators: with pSV = 3 bar
Heat generator capacity b = 40 kW VA = " [kW] × 13.5 l/kW and p0 = 1.5 bar
VA = 1.340 l
Panel radiators:
Panel radiators VA = " [kW] × 8.5 l/kW Example
rated temperature T = 70/50 °C → Vn = 140 l (for VA max. 1,460 l)
calculation
VA = 40 kW × 8.5 l/kW + 1,000 l = 1,340 l
Volume for Reflex N
buffer storage tank VPH = 1,000 l selected
1 × Reflex N 140, 6 bar, → page 11
Hst [m]
p0 ≥ bar + 0.2 bar 1 × cap ball valve, → page 20
10
13
p0 ≥ bar + 0.2 bar = 1.5 bar
10

22
 Selection and calculation

Heating Systems: 70/50 °C

Safety Valve pSV [bar] 5.0 6.0

Inlet Pressure p0 [bar] 2.0 2.5 3.0 3.5 4.0 2.0 2.5 3.0 3.5 4.0 5.0

Vn [litres] Contents VA [litres]

8 91 58 26 – – 118 90 63 35 7 –
12 136 88 39 – – 177 136 94 52 10 –
18 231 158 85 12 – 293 230 167 105 42 –
25 373 272 170 69 – 459 372 285 197 110 –
35 576 434 292 150 8 679 574 452 330 208 –
50 829 664 475 272 69 969 827 684 529 354 6
80 1,327 1,062 796 515 191 1,551 1,323 1,095 867 639 89
100 1,659 1,327 995 664 272 1,939 1,654 1,369 1,083 798 145
140 2,322 1,858 1,393 929 434 2,714 2,315 1,916 1,517 1,118 257
200 3,318 2,654 1,991 1,327 664 3,878 3,307 2,737 2,167 1,597 424
250 4,147 3,318 2,488 1,659 829 4,847 4,134 3,422 2,709 1,996 564
300 4,977 3,981 2,986 1,991 995 5,817 4,961 4,106 3,250 2,395 684
400 6,636 5,309 3,981 2,654 1,327 7,755 6,615 5,474 4,334 3,193 912
500 8,295 6,636 4,977 3,318 1,659 9,694 8,269 6,843 5,417 3,992 1,141
600 9,954 7,963 5,972 3,981 1,991 11,633 9,922 8,212 6,501 4,790 1,369
Reflex

800 13,271 10,617 7,963 5,309 2,654 15,511 13,230 10,949 8,668 6,387 1,825
1,000 16,589 13,271 9,954 6,636 3,318 19,389 16,537 13,686 10,835 7,984 2,281

Selecting expansion lines

Expansion lines are to be sized and installed in accordance
with local provisions. DIN EN 12828 requires that, each heat
generator is connected to at least one expansion line with
one or more expansion vessels. It is essential to ensure frost-
free conditions.

Expansion lines DN 25 DN 32 DN 40 DN 50 DN 65 DN 80 DN 100

1" 1¼" 1½" 2"

" /kW
2,100 3,600 4,800 7,500 14,000 19,000 29,000
Lengths ≤ 10 m

" /kW
1,400 2,500 3,200 5,000 9,500 13,000 20,000
Lengths > 10 m ≤ 30 m

If the length of the expansion line is > 10 m, we recommend selecting the nominal diameter one dimension larger.

23
Reflex

Comprehensive calculation and design notes

Before selecting the products, first collate the most important Z
The necessary basic data are preferable to be taken from the
system data for temperature, pressure and water content and design documents/manufacturer’s data. If these are not
calculate the parameters for selecting the products from this available, the data must be collected on site or estimated. Proxy
information. values for calculating and estimating the water volumes are
given in the tables. The extreme requirements of industrial heat
Water volume VA supply and district heat supply can be accommodated thanks to
the Variomat Giga.
Heat output !ges

Expansion volume flow "e

Water uptake volume V0

Safety valve actuating pressure pSV

Minimum operating pressure p0

Final pressure pE

Proxy values for calculation

Coefficient of expansion n for anti-freeze additives* z
z tmax °C 30 40 50 60 70 80 90 100 105 110 120 130 140 150

0% 0.37 0.72 1.15 1.66 2.24 2.88 3.58 4.34 4.74 5.15 6.03 6.96 7.96 9.03
n%
34 % 1.49 1.99 2.53 3.11 3.71 4.35 5.01 5.68 - 6.39 7.11 7.85 8.62 9.41

* Values apply for Antifrogen N. We recommend a concentration of 25 to 50 %. Lower doses lead to a risk of corrosion!

Evaporation pressure** pD for anti-freeze additives* z

z tmax °C 30 40 50 60 70 80 90 100 105 110 120 130 140 150

0% –0.96 –0.93 –0.88 –0.80 –0.69 –0.53 –0.3 0.01 0.21 0.43 0.98 1.7 2.61 3.76
pD bar
34 % –0.90 –0.80 –0.70 –0.60 –0.40 –0.10 – 0.23 0.70 1.33 2.13 3.15

* Values apply for Antifrogen N. We recommend a concentration of 25 to 50 %. Lower doses lead to a risk of corrosion!
** pD with respect to ±0 m NN, we recommend an additional 0.1 bar for each 1 km height.

Standard values for sizing expansion lines, make-up pipes and lines to control vessel
DN 20 25 32 40 50 65 80 100

1 630 1,040 1,830 2,410 3,700 6,960 9,450 14,130

" l/h
2 2,500 4,150 7,300 9,600 14,800 27,800 37,800 56,500

" permissible volume flow: 1 up to a maximum line length of 30 m

2 for a line length up to 1 m and to reductions, e. g. to vessel connections.
Not permissible for pressure controlled devices between pressure sensors and systems

When using anti-freeze, we recommend

remaining within 25–50 % glycol in order
to minimise the risk of corrosion.

24
 Selection and calculation

Estimating the volume of water in heat generators

The volume of water V W is calculated from the volume of water vW and the nominal performance of the heat generator "W or from the
installed collector area in solar panels AG.

Conventional heat generators vW l/kW

Cast iron boiler with atmospheric burner 1.10
Cast iron boiler with forced-air burner 1.40
Steel boiler with forced-air burner 1.80
Solid fuel boiler 2.00
VW = vW × !W
Wall-mounted condensing boiler 0.15
Heat exchanger 0.60
CHP 0.60
Heat pump 0.60
Solar panels vK l/m²
Flat panel 2.0
Direct vacuum tube 1.0 VK = vK × AG
Heat-pipe vacuum tube 3.0

Estimating the volume of water in heat surfaces and distribution lines

The volume of water VA is determined from the specific volume of water vA and the installed output of the heat consumer
unit " ges. It includes the water content of the heating surfaces, the distribution pipes and the pipelines in the central heating
system. Pipelines between the central heating plant and the heating system should be considered separately.

Types of heating surface tmax C | tR °C 90 | 70 70 | 55 70 | 50 55 | 45 45 | 35 35 | 30

Elements 11.5 17.6 18.1 27.7 44.6 83.3
Pipes 15 23.2 24.1 36.3 59.3 111.5
Plates 6.5 9.6 9.4 14.9 21.9 41.0
vA l/kW VA = vA × !ges.
Convectors 4 5.9 5.4 9.4 13.4 27.1
Ventilation 3.3 4.7 4.1 7.4 9.8 19.7
Underfloor heating system – – – – 21.1 35.6

Volume of vacuum spray pipe degasser VD ,which has to be absorbed by pressure maintenance
Degassing VD l
Servitec 25…30 1
Servitec 35…120 6
Special Servitec …–2…4 35
Special Servitec …–6…8 70

Specific volume of water VP in pipelines

The volume of water VP is determined from the specific volume of water vP and the length of the installed pipeline L.
Example for steel pipelines
DN 25 32 40 50 60 65 80 100 125 150 200
vP l/m 0.58 1.01 1.34 2.1 3.2 3.9 5.3 7.9 12.3 17.1 34.2

Example for plastic pipelines (PE_X pipes)

Model 20 × 2 25 × 2.3 32 × 2.9 40 × 3.7 50 × 4.6 63 × 5.8 75 × 6.8 90 × 8.2 110 × 10
di in mm 16 20 26 33 41 51 61 74 90
vP l/m 0.20 0.33 0.54 0.83 1.31 2.07 2.96 4.25 6.36

25
Reflex

Expansion vessels in heating systems

Calculation Pressure maintenance
To DIN 4807 T2 and DIN EN 12828. Static pressure maintenance with Reflex N, F, S, G also in
combination with make-up and degassing systems or as Variomat
Circuit
pressure maintenance station for pressure maintenance,
Usually maintaining suction pressure ( see sketch page 30)
degassing and make-up or as Reflexomat compressor controlled
with upstream flow-through pump and expansion vessel in the
pressure maintenance station.
return flow, i.e. on the suction side after the flow-through pump.
Degassing, venting, make-up
Material values n, pD
In order to achieve permanently safe automatic operation of the
Generally material values for pure water without anti-freeze.
heating system, it is advisable to fit the pressure maintenance
Expansion volume Ve, maximum temperature tTR devices with make-up systems and to supplement this with
Determine the percentage expansion generally between the Servitec degassing systems.
minimum temperature = fill temperature = 10 °C and the maxi-
Auxiliary vessel
mumnominal value setting for the temperature controller tTR.
If a temperature of 70 °C is permanently exceeded at the pressure
Minimum operating pressure p0 maintenance, an auxiliary vessel must be installed in order to
Particularly in the case of low-rise buildings and roof-mounted protect the bladders.
systems, the minimum supply pressure for the flow-through
Individual protection
pump is to be taken from the manufacturer’s specifications due to
According to DIN EN 12828, each heat generator must be
the low static pressure pst. We also recommend a minimum
connected to at least one expansion vessel. Only secured
operating pressure p0 of no less than 1 bar is selected for lower
shut-offs (against unintentional closure) are permitted. If a heat
static heads.
generator is hydraulically blocked (e.g. sequential switching of the
Note: Take care with low-rise buildings and roof-mounted
boiler), the connection to an expansion vessel must still be
systems Reflex recommendation: p0 ≥ 1 bar
guaranteed. In systems with more than one boiler, each boiler is
Filling pressure pF , supply pressure pa therefore usually secured with its own expansion vessel. This is
As the the filling temperature of 10 °C is generally the lowest only calculated for the respective boiler water content.
system temperature, the filling pressure = the supply pressure
for the expansion vessel. In pressure maintenance stations, it Due to the good degassing performance of Variomat
should be noted that the filling and make-up devices may have to pressure maintenance stations, we recommend to
run against the final pressure in some circumstances. This is only install an expansion vessel (e.g. Reflex N) is installed at
the case with Reflexomat. the heat generator in order to minimise the switching
frequency, even on single boiler systems.
Use Refix for systems where corrosion
is a potential risk!
In systems with oxygen-rich water (e.g. geothermal
systems or underfloor heating without any
impermeable pipes), Refix D, Refix DE or Refix C
is used up to 70 °C as all water-bearing parts are
corrosion protected.

In order to achieve permanently safe automatic

operation in cooling water systems, it is advisable
to fit the pressure maintenance devices with
make-up systems and to supplement this with
Servitec degassing systems. This is particularly
important in cooling water systems as there must be
no thermal deaeration effects.

26
 Selection and calculation

Expansion vessel calculation in heating systems

Circuit: Maintaining supply pressure, expansion vessel in the return flow, upstream flow-through pump, follow-up pressure maintenance.

Initial data see manufacturer’s specifications/proxy values for calculation

Heat generator
… heat output "W [kw] Total for all heat generators !ges = ... kw
… volume of water VW [l]
Design
… inlet temperature tV [°C]
… return flow temperature tR [°C] At tR > 70 °C install auxiliary vessel!
Volume of water VA [l] VA = ... Litres
Maximum target value setting
Temperature controller tTR [°C]
Anti-freeze additive [%] Percentage expansion n (with anti-freeze additive n*) n = ... %
Safety temperature limiter tSTB [°C] Evaporation pressure pD at > 100 °C (with anti-freeze additive pD*) pD = ... bar
Static pressure pst [bar] pst = ... bar
Pressure calculation
p0 = pst + pD + 0.2 bar (safety factor)
Reflex recommendation: p₀ ≥ 1.0 bar
Supply pressure p0 [bar] p0 = ... bar
Req. Check supply pressure for flow-through pump (NPSH value) from manufacturer’s
specifications and maintenance of permissible operating pressure.
Reflex recommendation:
Safety valve
for pSV ≤ 5 bar: pSV ≥ p₀ + 1.5 bar pSV = ... bar
actuating pressure pSV [bar]
for pSV > 5 bar: pSV ≥ p₀ + 2.0 bar
pe ≤ pSV – final pressure differential
Final pressure pe [bar] for pSV ≤ 5 bar: pe ≤ pSV – 0.5 bar pe = ... bar
for pSV > 5 bar: pe ≤ pSV – 0.1 × pSV
Expansion vessel
n
Expansion volume Ve [l] Ve = × VA Ve = ... litres
100

Water reservoir VV [l] VV = 0.005 × VA at least 3 l for Vn > 15 l VV = ... litres

minimum water seal volume to standard
pe + 1
for Vn > 15 l: Vn = (Ve + VV + VD*) ×
pe − p0
Nominal volume Vn [l] for Vn ≤ 15 l: Water reservoir VV ≥ 0.2 × Vn Vn = ... litres
pe + 1
Vn = (Ve + VV + VD*) ×
pe − p0
Note: The pressure factor is used for simplified calculation of the nominal volume,
which is larger than the water reservoir + expansion volume by the pressure factor.
pe + 1
pa = − 1 bar
(Ve + VD*) (pe + 1) (n + nR)
1+
Control supply pressure pa [bar] Vn (p0 + 1) 2n pa = ... bar
Precondition: pa ≥ p0 + 0.25…0.3 bar,
otherwise calculate for larger nominal volume
Result
Reflex …/ … bar …litres p0 = ... bar Check before commissioning!
pa = ... bar Check make-up setting!
pe = ... bar

* Only applies when using Reflex Servitec in accordance with the ‘Degassing’ table see page 25

27
Reflex

Expansion vessels in cooling water systems

The calculation is carried out in accordance with DIN EN 12828 Degassing, venting, make-up
and DIN 4807 part 2. In order to achieve permanently safe automatic operation in
cooling water systems, it is advisable to fit the pressure mainte-
Material values n* nance devices with make-up systems and to supplement this with
Anti-freeze additives (recommendation: 25–50 % concentration), Servitec vacuum spray pipe degassing systems. This is particularly
depending on the lowest temperature of the system,must be important in cooling water systems as there must be no thermal
taken into consideration when determining the percentage deaeration effects.
expansion n* according to the manufacturer's specifications.
Auxiliary vessels
Expansion volume Ve The Reflex bladders are suitable for temperatures as low as
Determination of the percentage expansion n* generally between − 20 °C and the vessels to − 10 °C however, this does not mean the
the lowest system temperature (e.g. downtime during winter bladder will not ‘freeze up’ in the vessel. We therefore recom-
− 20 °C) and the highest system temperature (e.g. downtime mend an auxiliary vessel is installed in the return flow to the
during summer +40 °C). chiller at temperatures ≤ 0 °C.
Minimum operating pressure (supply pressure) p0 Individual protection
As temperatures do not exceed 100 °C, special factors are not As with heating systems, we recommend individual protection if
required. there is more than one chiller.
Filling pressure pF , supply pressure pa
The lowest system temperature is frequently less than the filling
temperature which means the filling pressure is greater than the
supply pressure.
Pressure maintenance
Generally used for static pressure maintenance with Reflex,
also in combination with Control and Servitec make-up and
degassing stations.

In order to achieve permanently safe automatic

operation in cooling water systems, it is advisable to
fit the pressure maintenance devices with make-up
systems and to supplement this with Servitec
degassing systems. This is particularly important in
cooling water systems as there must be no thermal
deaeration effects.

28
 Selection and calculation

Expansion vessel calculation in cooling water systems

Circuit: Maintaining supply pressure, expansion vessel on the suction side, flow-through pump, with follow-up pressure maintenance.

Initial data see manufacturer’s specifications/proxy values for calculation

Return flow temperature tR [°C] To the chiller; at tR > 70 °C install auxiliary vessel!
Inlet temperature tV [°C] From the chiller
Minimum system temp. tSmin [l] e. g. downtime during winter
Maximum system temp. tSmin [l] e. g. downtime during summer
Anti-freeze additive [%] Percentage expansion with anti-freeze additive n* n* = … %
Between minimum temperature (–20 °C) and
Percentage expansion [%] n*F = … %
filling temperature (usually 10 °C)
Static pressure pst [bar] pst = … bar
Pressure calculation
p0 = pst + 0.2 bar (safety factor)
Supply pressure p0 [bar] Reflex recommendation: p₀ ≥ 1.0 bar p0 = … bar
Check permissible operating pressure is maintained.
Reflex recommendation:
Safety valve
for pSV ≤ 5 bar: pSV ≥ p₀ + 1.5 bar
actuating pressure pSV [bar] pSV= … bar
for pSV > 5 bar: pSV ≥ p₀ + 2.0 bar
pe ≤ pSV – final pressure differential to TRD 721
Final pressure pe [bar] for pSV ≤ 5 bar: pe ≤ pSV – 0.5 bar pe =… bar
for pSV > 5 bar: pe ≤ pSV – 0.1 × pSV
Expansion vessel
System volume VA [l] VA = chiller + cooling coil + pipelines + buffer storage + other VA = … litres

Water reservoir VV [l] VV = 0.005 × VA at least 3 l for Vn > 15 l VV = ... litres

minimum water seal volume to standard
pe + 1
for Vn > 15 l: Vn = (Ve + VV + VD*) ×
pe − p0
Nominal volume Vn [l] for Vn ≤ 15 l: Water reservoir VV ≥ 0.2 × Vn Vn = … litres
pe + 1
Vn = (Ve + VV + VD*) ×
pe − p0

pe + 1
pa = − 1 bar
(Ve + VD*) (pe + 1)
1+
Control supply pressure pa [bar] Vn (p0 + 1) pa = ... bar
Precondition: pa ≥ p0 + 0.25…0.3 bar,
otherwise calculate for larger nominal volume
Result
Reflex …/ … bar …litres p0 = … bar Check before commissioning!
pa = … bar Check make-up setting!
pF = … bar Refill the system!
pe =… bar

* Only applies when using Reflex Servitec in accordance with the ‘Degassing’ table see page 25

29
Reflex

Expansion vessels in solar systems

The calculation is carried out in accordance with VDI 6002 and Supply pressure p0 , minimum operating pressure
DIN 4807 part 2. Depending on the calculation method, the minimum operating
pressure (= supply pressure) is adjusted to the downtime
Solar systems have a peculiarity in that the maximum tempera- temperature in the panel (= without evaporation) or the boiling
ture cannot be defined by the controller on the heat generator but temperature (= with evaporation). In both cases, the usual circuit
is determined by the downtime temperature on the panel. for the circulating pump ΔpP stated above is to be taken into
consideration as the expansion vessel is connected downstream
Nominal volume calculation without evaporation in the panel
of the flow-through pump on the pressure side (follow-up
The percentage expansion n* and the evaporation pressure pD*
pressure maintenance).
are related to the downtime temperature. As a temperature of
over 200 °C can be reached on certain panels, this calculation Filling pressure pF , supply pressure pa
procedure is no longer valid at this point. Some indirectly heated The filling temperature (10 °C) is usually well above the minimum
pipe panels (system heat pipe) systems have a limit on the system temperature which means the filling pressure is greater
downtime temperature. If a minimum operating pressure of p0 ≤ than the supply pressure.
4 bar is sufficient to avoid evaporation, the calculation can usually
Auxiliary vessels
be completed with evaporation. In this variant, it should be noted
If a stable return flow temperature of ≤ 70 °C cannot be
that increased temperature loading reduces the anti-freeze effect
guaranteed on the consumer side, an auxiliary vessel is to be
of the heat transfer medium in the long term.
installed on the expansion vessel.
Nominal volume calculation with evaporation in the panel
Evaporation cannot be excluded in panels with downtime
temperatures over 200 °C. The evaporation pressure is only taken
into consideration up to the required evaporation point
(110 – 120 °C). In this instance, the total panel volume VK is taken
into consideration in addition to the expansion volume Ve and the
water reservoir V V when determining the nominal volume of the
expansion vessel. This variant is preferred as the lower tempera-
ture places less strain on the heat transfer medium and the frost
TI PI
protection effect has a longer duration.
Material values n*, pD*
Anti-freeze additives of up to 40 % are to be taken into
consideration when establishing the percentage expansion n*
and the evaporation pressure pD* in accordance with manufactur-
ers’ specifications. If evaporation is included in the calculation,
the evaporation pressure pD* is taken into account up to the
boiling point of 110 °C or 120 °C. The percentage expansion n* is
then determined between the lowest external temperature
(e. g. –20 °C) and the boiling temperature. If evaporation is not
included in the calculation, the evaporation pressure pD* and the
percentage expansion n* are dependent on the downtime
temperature of the panel.

30
 Selection and calculation

Expansion vessel calculation in solar systems

Circuit: follow-up pressure maintenance, expansion vessel in the return flow to the panel.

Initial data see manufacturer’s specifications/proxy values for calculation

Panels
Total of all panels VKges = … litres
Volume of water VK [l]
Maximum inlet temp. tV [°C] (110 °C or 120 °C for solar systems with evaporation)
Minimum external temp. ta [°C] -20 °C
Anti-freeze additive [%] Percentage expansion with anti-freeze additive n* n* = … %
and evaporation pressure with anti-freeze additive pD* pD* = … bar
Between minimum temperature (–20 °C) and
Percentage expansion [%] n*F = … %
filling temperature (usually 10 °C)
Static pressure pst [bar] pst = … bar
Evaporation pressure pD at > 100 °C
Differential at the (For anti-freeze additive pD*)
flow-through pump ΔpP [bar] Req. Check supply pressure forflow-through pumps according to manufacturers’ ΔpP = … bar
specifications.
Pressure calculation
p0 = pst + ΔpD + pD*
Supply pressure p0 [bar] p0 = … bar
Check permissible operating pressure is maintained.
Reflex recommendation:
Safety valve
for pSV ≤ 5 bar: pSV ≥ p0 + 1.5 bar
actuating pressure pSV [bar] pSV = … bar
for pSV > 5 bar: pSV ≥ p0 + 2.0 bar
pe ≤ pSV – final pressure differential to TRD 721
Final pressure pe [bar] for pSV ≤ 5 bar: pe ≤ pSV – 0.5 bar
pe = … bar
for pSV > 5 bar: pe ≤ pSV – 0.1 × pSV
Expansion vessel
System volume VA [l] VA = cooling coil + pipelines + buffer storage + other VA = … litres
Expansion volume Ve [l] Ve = × VA Ve = … litres
VV = 0.005 × VA at least 3 l for Vn > 15 l
Water reservoir VV [l] VV = … litres
minimum water seal volume to standard
pe + 1
for Vn> 15 l: Vn = (Ve + VV + VKges*) × pe − p0

Nominal volume Vn [l] Vn = … litres

for Vn≤ 15 l: Water reservoir VV ≥ 0.2 × Vn
pe + 1
Vn = (Ve + VV + VKges*) × pe − p0

pe + 1
vpa = – 1 bar
(Ve + VKges*) (pe + 1)
Control 1+
Vn (p0 + 1) 2n pa = … bar
Supply pressure pa [bar]
Precondition: pa ≥ p0 + 0.25…0.3 bar,
otherwise calculate for larger nominal volume
Filling pressure pF [bar] pF = Vn × – 1 bar pF = … bar
Result
Reflex S /… bar … litres p0 = … bar Check before commissioning!
pa = … bar Check make-up setting!
pF = … bar Refill the system!
pe =… bar
* Only applies when using Reflex Servitec in accordance with the ‘Degassing’ table see page 25

31
 Reflex

Installation and commissioning

Hydraulic integration
Z
Integration should preferably be on the suction side of the Z
Expansion lines are to be sized and installed in accordance with
flow-through pump and in the return flow to the boiler, solar local provisions. DIN EN 12828 requires that each heat generator
panel or chiller is connected to at least one expansion line with one or more
expansion vessels. It is essential to ensure frost-free conditions.
Z
At return temperatures of > 70 °C a V auxiliary vessel is required,
at return temperatures of < 0 °C, it is recommended. Z
Make-up pipes are to be integrated into the flow-through facility
water, not into the expansion line.
Z
Provide a secured shut-off with drain to DIN EN 12828
(applies to all hydraulic systems) for maintenance work
(order separately). In larger systems, it is also possible to
arrange the drain and shut-off separately.

The relevant assembly and operating instructions

are to be taken into consideration when installing
and commissioning.

Supply pressure maintenance (suction pressure maintenance)

Vor-/Saug The pressure maintenance is integrated upstream of

pz Δpp the flow-through pump, i.e. on the suction side. This
pzul method is used almost exclusively because it is the
A sv
easiest to control.
pSV pzul
Operating Z
Benefits:
pressure
+ low idle pressure level
+ working pressure → idle pressure, therefore
pSV no risk of vacuum formation
A sv
pa
Idle pressure target value
Z
Disadvantages:
pe
pa, pe p0, pz
– at high flow-through pump pressure
(large systems) with high working pressure,
observe the network load pzul

Follow-up pressure maintenance

Pressure maintenance is integrated downstream of the
flow-through pump, i.e. on the pressure side. When
determining the idle pressure, a facility-specific differen-
pSV, pzul
A sv tial pressure component for the flow-through pump
pe
Idle pressure target value (50 ... 100 %) must be included in the calculation. For use
pSV pzul pa
p0
in only a limited number of cases → solar systems.
Δpp
Operating
Z
Benefits:
pressure + low idle pressure level providing the entire pump
pressure does not have to be loaded
Δpp pz
pz
Z
Disadvantages:
pa, pe – high idle pressure
– greater attention to maintaining the required
supply pressure pZ in accordance with
manufacturers’ specifications

32
 Installation and commissioning

Integrating multi-boiler systems

It is possible to have either individual protection for each boiler
with an expansion vessel or overall boiler and system protection.
Care should be taken to ensure the relevant boiler remains
connected to at least one expansion vessel when shutting off the
boiler’s sequential switching. Always agree the best switching
sequence with the boiler manufacturer. The system pressure and
the medium characteristics (glycol component) must be the same
in both circuits.

Reflex N serial circuit in a multi-boiler system with individual protection

The serial circuit of several Reflex N 6 or 10 bar
TIC
vessels generally produces economical alternatives to
Reflex G large vessels.
With the burner, the corresponding boiler circuit pump
TIC TIC
is switched off via the temperature control and
the motor valve is closed. The boiler remains
connected to its Reflex vessel. The most frequent
switching occurs with boilers with minimum return
temperature. Switching the burner off reliably
TIC TIC
prevents circulation via the boiler.

Reflex in a multi-boiler system with common boiler and system protection

When the burner is switched off, the final control
TIC element is closed by the temperature controller
preventing incorrect circulation via the shut-off
TIC TIC
boiler. Joining the boiler expansion line above the
centre of the boiler prevents gravity circulation.
Preferred inset in systems without minimum boiler
return flow temperature (e.g. condensing boiler
systems).

The diagrams serve only as illustrations of the connections.

They are to be amended to local conditions and to be made more specific.

33
Reflex

Systems with pipework at risk of corrosion

Underfloor heating without any impermeable pipes
Z
In systems with oxygen-rich water such as under-
floor heating without any impermeable pipes,
we recommend the systems are separated
TS+ TC
(separate the boiler heating circuit medium from
the oxygenrich underfloor heating circuit medium)
using a Longtherm heat exchanger.
Refix DE
Z
A Refix expansion vessel is used in underfloor
heating circuits due to the risk of corrosion
(corrosion protection for all water-bearing parts).

Longtherm heat exchanger

Reflex N

Maintaining VDI 2035

Z
To ensure compliance with VDI 2035, use a Fillsoft
housing with a softening or demineralising cartridge
(depending on the quality of the water or the
Reflex N specifications of the operator/boiler manufacturer).
Fillsoft external Fillcontrol Plus Compact
pressure sensor Z
The Fillcontrol Plus Compact automatic make-up
station which also has a system separator for the
potable water supply system ensures an adequate
water reservoir.
Fillmeter

Fillsoft I

* DN 15 < 2 m connection pipe

DN 20 < 10 m connection pipe
DN 25 > 10 m connection pipe

The directive VDI 2035 describes the state of the art for water
quality in hot water heating systems and contributes to min-
imising damage due to corrosion and scale deposits in these
systems. The Fillsoft series of Reflex products comply with this
directive. Further information can be found in our Make-up and
Water Treatment brochure.

34
 Installation examples

Installation examples
Reflex vessel with automatic make-up Solution N-o 01
We recommend the
use of an automatic
make-up such as
Reflex Fillcontrol
Plus Compact
combined with static
Servitec Mini pressure mainte-
nance in order to
Reflex ensure an adequate
water seal.

Servitec vacuum
spray pipe degassing
and the dirt and
SINUS MultiFlow Domestic sludge separators
remove disruptive
factors such as
Exdirt gasses and dirt from
the facility water.

Refix
FE external pressure sensor Fillguard

Storatherm Aqua Fillcontrol

Plus Compact

Fillsoft I

Reflex with flaw detector Solution N-o 04

Reflex vessel
with flaw detector
Exvoid T Exvoid T for monitoring the
bladder (from
1,000 litres and
Ø 1,000 mm).
Storatherm Heat

A Longtherm heat
M M
exchanger is used to
Exdirt separate the heating
and potable water
>500 mm
.

circuit.
Compact distributor
Kompaktverteiler

Fillset Impuls acts as

a system separator to
the potable water
Fillset supply system. The
Impuls contact water meter
for determining
filling and make-up
Fillsoft I quantities is
Exdirt V
connected with the
Longtherm Servitec controller
and evaluated by it.

Servitec 35

Reflex

35
Reflex

Operation & Maintenance

Industrial Safety Regulations require expansion vessels to be
checked on an annual basis. The relevant notes for installers and
operators in the Reflex Assembly, Operating and Maintenance
Instructions are to be observed.

1. Visual inspection
Z
Inspect vessel for damage, corrosion, etc.
In the event of damage, complete repairs or replace and determine the possible cause.
Z
Match vessel suitability to on-site use.

2. Check bladder
Briefly activate the gas filling valve. If water leaks out:
Z
For vessels which do not have a facility for replacing the bladder,
replace the expansion vessel.
Z
for vessels which have a facility for replacing the bladder, replace the bladder
or alternatively contact Reflex Service for further advice.

3. Setting gas supply pressure

Isolate the Reflex vessel from the system using the cap valve
and empty on the water side (check system pressure).
Measure supply pressure p0 at the gas filling valve and if necessary reset
to the required minimum operating pressure for the system.
p0 [bar] = pst + 0,2 bar + pD* + ∆pp**
* Evaporation pressure pD only relevant for hot water systems >100 °C.
** Used to maintain follow-up pressure maintenance (expansion vessel downstream of the pump on the pressure)
e.g. In solar thermal systems.
Z
If the pressure is too high, blow off the gas with the gas filling valve.
Z
If the pressure is too low, refill with nitrogen from a pressurised container.
Z
Enter the reset or corrected supply pressure p0 on the type plate.

4. Functional inspection during operation

Z
Close drain at the cap valve and carefully open cap valve.
Z
Note system pressure and do not allow it to fall below p0.
Z
Fill the system up to the filling pressure pF in accordance with the system temperature.

pF [bar] ≥ p0 + 0,3 bar (at filling temperature 10 °C)

Z
Checking gas pressure during operation: the gas pressure must now be the same as
the system pressure (working vessel).

5. Gas filling valve leak test

Remove optional aids for filling and measuring at the gas filling valve and inspect with leak test
spray to see whether the gas filling valve leaks after use. Finally, refit the cap valve, which
provides the seal, on the gas filling valve.

36
 Selection and calculation

Selection and calculation

Pressures in the system
Applies to expansion vessels in hot water heating systems

Excess pressures
pst = static pressure
p0 = minimum operating pressure psv
pa = supply pressure
pe = final pressure pe ≤ pSV − 0.5 bar
psv = safety valve actuating pressure (Reflex recommendation)

pa

p0 = pa − 0.2…1 bar

Safety valve actuating pressure

pressure reducer set value
Gas supply pressure

Supply pressure /

System pressure
Final pressure
p0

pa

pe

PI

Application limits according to DVGW

The following design parameters in accordance with DIN 4708 part 5
are decisive when using MAG-W:
Potable water heater capacity VSp in l
Nominal volume of the MAG-W Vn in l
Safety valve actuating pressure psv = 6.0 or 10.0 bar
Working pressure differential dpA = 20 % of pSV in bar
Facility pressure (pe = pSV – dpA) pe = 4.8 or 8.0 bar
Supply pressure in the MAG-W p0 = pa–0.2 in bar
Supply pressure pa pa in bar
(idle pressure behind the pressure reducer)
Cold water temperature tw = 10 °C constant
Hot water temperature tww = 60 °C constant
Water expansion n = 1.67 %

51
Refix

Refix quick selection

Selection by nominal volume Vn
Vn
! pa pSV VSp
p0
!S
10 °C Cold water feed temperature
60 °C Vessel temperature

Z
Gas supply pressure p0 = 3.0 bar Z
Gas supply pressure p0 = 4.0 bar = standard
Z
Pressure reducer Z
Pressure reducer
preset pressure pa ≥ 3.2 bar preset pressure pa ≥ 4.2 bar

Gas inlet pressure p0 [bar] 3.0 4.0 = standard

Pressure reducer set-point pressure pa [bar] ≥ 3.2 ≥ 4.2
Safety Valve pSV [bar] 6 7 8 10 6 7 8 10
Vsp [litres] Vn [litres]
90 8 8 8 8 8 8 8 8
100 8 8 8 8 12 8 8 8
120 8 8 8 8 12 8 8 8
130 8 8 8 8 12 8 8 8
150 8 8 8 8 18 12 8 8
180 12 8 8 8 18 12 8 8
200 12 12 8 8 18 12 12 8
250 12 12 12 8 25 18 12 12
300 18 18 12 12 25 18 18 12
400 25 18 18 18 33 33 15 25
500 25 25 18 18 60 33 25 25
600 33 25 25 18 60 60 33 25
700 33 33 25 25 60 60 33 25
800 60 33 33 25 80 80 60 25
900 60 60 33 25 80 60 60 33
1,000 60 60 33 33 100 60 60 60
1,500 80 80 60 60 200 100 80 60
2,000 100 100 80 80 200 200 100 80
Refix

3,000 100 100 100 100 300 200 200 100

Key data Selection Result

Vessel volume Vsp = 900 litres Safety valve psv = 10.0 bar From the table

Hot water temperature Tww = 60 °C Expansion (60 °C/10 °C) n = 1.7 % Vessel volume → Vn = 31.5 litres Selection
example
Pressure reducer Supply pressure p₀ = 4.0 bar
preset pressure pa = 4.2 bar

52
 Selection and calculation

Selection by peak volume flow Vs

In potable water expansion vessels with flow-through, determining just the
nominal volume Vn is not enough. Further checks are to be carried out to Flowjet
establish whether the maximum recommended peak volume flow Vs has not !S !S
been exceeded as well as the pressure drop Δp.
! !
T-piece
Once the nominal volume of the Refix has been selected, checks must be Dual connection
carried out on vessels with flow-through to establish whether the peak
volume flow !s, resulting from the calculation of the pipe network in
10 °C Cold water feed temperature
accordance with DIN 1988 can be implemented on the Refix vessels. If a
larger nominal connection diameter is required, for Refix DD, a 60 litre Refix 60 °C Vessel temperature
DT is to be used instead of the 8–33 litre vessel for greater flow.

recommended actual pressure loss

Available connections
max. peak volume flow "S* at volume flow "

Refix DD 8–33 l

with or without Flowjet Rp ¾" = standard ≤ 2.5 m³/h ∆p = 0.03 bar × ( 2.5! m³/h
m³/h )
²

passing T-piece Rp 1" (on-site) ≤ 4.2 m³/h negligible

Refix DT 60–500 l

with Flowjet Rp 1¼" ≤ 7.2 m³/h ∆p = 0.04 bar × ( 7.2! m³/h

m³/h )
²

Refix DT 80–3.000 l

Dual connection DN 50 ≤ 15 m³/h ∆p = 0.14 bar × ( 15! m³/h

m³/h )
²

Dual connection DN 65 ≤ 27 m³/h ∆p = 0.11 bar × ( 27! m³/h

m³/h )
²

Dual connection DN 80 ≤ 36 m³/h negligible

Dual connection DN 100 ≤ 56 m³/h negligible

Refix DE, DC

(no medium circulating) unlimited ∆p = 0

* determined for a speed of 2 m/s

53
Refix

Comprehensive calculation and design notes

Potable water is a food stuff. Expansion vessels in potable water
installations therefore have to meet specific requirements to
DIN 4807 part 5. Only vessels with flow-through are permitted.

Refix in water heating systems

Calculation
The calculation is completed in accordance with
DIN 4807 part 5 see next page

Circuit

Vn
" pa pSV VSp
p0
"S

The safety valve is usually installed directly at the cold water Refix DD with T-piece: Rp ¾" max. 200 l water heater
inlet on the water heater. On Refix DD and DT, the safety valve Rp 1" max. 1,000 l water heater
may also be installed immediately upstream of the flow
through, shut-off and drain valve when viewed from the Refix DT flow-
direction of flow if the following conditions are met: through fitting: Rp 1¼" max. 5,000 l water heater

Material values n, pD Supply pressure pa

Usually determined between cold water temperature 10 °C and This is identical to the preset pressure on the pressure reducer.
maximum hot water temperature 60 °C. Pressure reducers to DIN 4807 part 5 are required in order to
achieve a stable supply pressure and therefore the full capacity
Thermal disinfection of the Refix.
With thermal disinfection, the entire hot water network is heated
to > 70 °C. As expansion vessels are installed in the cold water feed, Expansion vessel
they are not affected by the increased temperature. If thermal In potable water systems to DIN 1988, only Refix vessels
disinfection is included, this must only be included in the calculation. with flow-through to DIN 4807 part 5 may be used. Refix with
a connection may be used for non-potable water.
Supply pressure p0, minimum operating pressure
The minimum operating pressure or supply pressure p0 in the
expansion vessel must be at least 0.2 bar less than the minimum
flow pressure. Depending on the distance between the pressure
reducer and the Refix, supply pressure settings of 0.2 to 1.0 bar less
than the preset pressure on the pressure reducer are required.

54
 Selection and calculation

Initial data see manufacturer’s specifications/proxy values for calculation

Vessel volume VSp [l]

Heat output "W [kW]
Water temperature tWW [°C] Depending on the controller setting 50 … 60 °C

Percentage expansion [%] n = ... %

Pressure reducer pa [bar] Setting pressure pa = … bar

Safety valve pSV [bar] Reflex recommendation: 10 bar pSV = … bar
Peak flow !S [m³/h] "S = … [m³/h]

Selection by nominal volume Vn

p0 = pa − (0.2 … 1.0 bar) p0 = … bar

Supply pressure p0 [bar] Set supply pressure 0.2 ... 1.0 bar less than pressure reducer
(depending on distance between pressure reducer and Refix)

n × (psv + 0.5) ( p0 + 1.2)

Nominal volume Vn [l] Vn = VSp × Vn = … litres
100 × (p0 + 1) (psv – p0 – 0.7)

Selection by peak volume "S

Once the nominal volume of the Refix has been selected, checks must be carried out on vessels with
flow-through to establish whether the peak volume flow !s , resulting from the calculation of the
pipe network in accordance with DIN 1988 can be implemented on the Refix vessels. If this is the
case, for Refix DD, a 60 litre Refix DT is to be used instead of the 8–33 litre vessel for greater flow.
Alternatively, a Refix DD with a suitably larger T-piece can be used whereby it should be noted that
the flow-through insert of the DD vessel protrudes into the full bore of the T-piece.
recommended max. actual pressure loss
Available connections
peak volume flow "S* at volume flow "

mit oder ohne Flowjet

Rp ¾" =
Standard
≤ 2,5 m³/h ∆p = 0,03 bar × ( 2,5! m³/h
m³/h )
²
Refix DD
8–33 l

Durchgang T-Stück Rp 1" (bauseits) ≤ 4,2 m³/h vernachlässigbar

Flowjet
!S

( )
60–500 l

! m³/h ²
Refix DT

mit Flowjet Rp 1¼" ≤ 7,2 m³/h ∆p = 0,04 bar ×

7,2 m³/h !
T-piece
∆p = … bar
Duo-Anschluss DN 50 ≤ 15 m³/h ∆p = 0,14 bar × ( 15! m³/h
m³/h )
²

!S G =…
Duo-Anschluss DN 65 ≤ 27 m³/h ∆p = 0,11 bar × ( 27! m³/h
m³/h )
²
80–3.000 l

!
Refix DT

Duo-Anschluss DN 80 ≤ 36 m³/h vernachlässigbar

Dual connection
Duo-Anschluss DN 100 ≤ 56 m³/h vernachlässigbar
Refix DE,
Refix DC

(nicht durchströmt) unbegrenzt ∆p = 0

* ermittelt für eine Geschwindigkeit von 2 m/s

Result

Refix DT5 …… l Vn = … l

Refix DD …… l
G = …… (Standard Rp 3/4" incl.) p0 = … bar

Refix DT5 …… l

55
Refix

Refix in pressure booster systems

Potable water is a food stuff. Expansion vessels in potable
water installations therefore have to meet specific requirements
to DIN 4807 part 5. Only vessels with flow-through are permitted.

Calculation
The calculation is completed in accordance with DIN 1988 part 5,
Codes of practice for drinking water installations, pressure
boosting and pressure reduction.

Circuit

Refix in pressure booster systems Refix in pressure booster systems

Suction side Pressure side

pe pe
Connection pipe

Connection pipe

pa pa, pe pa
p0 pmax /pSV p0
pmax /pSV
pVmax

pminV

On the upstream side of a pressure boosting system (DEA), On the downstream side of a pressure booster system (DEA)
Refix expansion vessels relieve the pressure on the connection the switching frequency is reduced when installing Refix,
pipe and the supply network. Installation is to be agreed with particularly in cascade controlled systems. Installation on both
the water supply company. sides of the DEA may be necessary.

Supply pressure p0, supply pressure pa

The minimum operating pressure or the supply pressure p0
in the Refix must be set to approximately 0.5 to 1 bar less than the
minimum supply pressure when installed on the suction side and
0.5 to 1 bar less than the cut-in pressure on the pressure
side of a DEA. As the supply pressure pa is at least 0.5 bar greater
than the supply pressure, there is always an adequate water
reservoir available which is an important precondition for
low-wear operation.

In potable water systems to DIN 1988, only Refix vessels

with flow-through to DIN 4807 part 5 may be used. Refix with
a connection may be used for non-potable water.

Care should be taken to ensure the pressure

surges do not exceed the maximum permissible
operating pressure.

56
 Selection and calculation

Suction side circuit: Refix on the upstream side of the DEA

Installation is to be agreed with the relevant water supply Z
if a pump fails in the DEA, the flow speed in the connection pipe
company. This is necessary if the following criteria cannot of the DEA may not alter by more than 0.15 m/s
be met: Z
if all the pumps fail, by not more than 0.5 m/s
Z
when the pump is in operation, the minimum supply pressure
pminV may not drop below 50 % and must be at least 1 bar

Initial data see manufacturer’s specifications/proxy values for calculation

Selection in accordance with DIN 1988 part 5

max. feed flow Refix DT with twin Refix DT

min. supply pressure pminV [bar] "maxP / m³/h connection Vn / litre Vn / litre
Vn = ... litres
max. feed flow !maxP [m³/h] ≤7 300 300
> 7 ≤ 15 500 600
> 15 – 800

Supply pressure p0 [bar] p0 = pminV – 0.5 bar p0 = ... bar

Result
Refix DT5 ....... l Vn = ... l
with twin connection DN 50 p0 = ... bar
Refix DT5 ....... l

Pressure side circuit Refix on the downstream side of the DEA

Initial data see manufacturer’s specifications/proxy values for calculation
For limiting the switching frequency in pressure-controlled systems
Max. pump head for the DEA Hmax [mWs]
Max. supply pressure pmax [bar]
Cut-in pressure pE [bar]
Cut-out pressure pA [bar] s − Switching frequency 1/h 20 15 10
Max. feed flow !maxP [l/h]
Switching frequency s [1/h] Pump output kW ≤ 4.0 ≤ 7.5 ≤ 7.5
No. of pumps n [pieces]
Electrical power of the
more powerful pump Pel [kW]

pA + 1
Nominal volume Vn [l] Vn = 0,33 × VmaxP Vn = ... litres
(pA − pE) × s × n

For storing the minimum feed quantity Ve between On and Off for the DEA
Cut-in pressure pE [bar]
Cut-out pressure pA [bar]
Reflex recommendation: for p0 = pE − 0,5 bar p0 = ... bar
Refix supply pressure p0 [bar]
Feed quantity Ve [l]

(pE + 1) (pA + 1)
Nominal volume Vn [l] Vn = Ve Vn = ... litres
(p0 + 1) (pA − pE)

Check permissible Hmax [mWs]

pmax = ≤ 1,1 pzul pmax = ... bar
operating excess pressure pmax [bar] 10

Initial data
Refix DT5 ....... l Vn = ... l
with twin connection DN 50 Vn = ... l
Refix DT5 ....... l p0 = ... bar

57
Refix

Installation examples
Refix in water heating systems–installation examples
Refix DD, DT 60–500 with Flowjet flow through, shut-off and drain valve
Z
The complete solution with Flowjet flow through,
shut-off and drain valve
Z
Benefits: Flowjet is easy to fit and DIN-compliant
Guaranteed shut off, drainage and flow-through
1
for Refix.

4 3
1 Refix DD or Refix DT 60–500
2 Flowjet flow through, shut-off and drain valve
optional accessory for Refix DD:
2 Z
standard with T-piece Rp ¾", ! ≤ 2. 5 m³/h
Z
for T-piece Rp 1" ! ≤ 4.2 m³/h
for Refix DT 60–500’ with Flowjet:
Z
standard with Rp 1¼" ! ≤ 7.2 m³/h
3 Reflex wall-hung holder for 8–25 litres
(33 l with butt straps, DT with feet)
4 A safety valve may also be fitted upstream in
the direction of flow of the Refix DD or the DT5
with Flowjet provided the nominal diameter of
the required SV ≤ than the downstream
storage feed.
Refix DD without Flowjet flow through, shut-off and drain valve
Z
If no Flowjet flow through, shut-off and drain valve is
fitted, the feed to the water heater must be shut-off
during maintenance work and the Refix DD drained
via an on-site fitting.
1 1 Refix DD
2 T-piece Rp ¾", ! ≤ 2.5 m³/h
3
For T-piece Rp 1" ! ≤ 4.2 m³/h
3 Reflex wall-hung holder for 8–25 litres
2 (33 l with butt straps feet)

Refix DT with twin connection

Z
Additional fittings are required when shutting off
and draining the Refix DT with twin connection.
Z
The safety valve can not be shut off at the cold water
inlet on the vessel.

Vessel charging systems are sometimes

subjected to high temperatures. Please
contact your Reflex representative.

58
 Operation & Maintenance

Operation & Maintenance

Industrial Safety Regulations require expansion vessels to be
checked on an annual basis. The relevant notes for installers and
operators in the Reflex Assembly, Operating and Maintenance
Instructions are to be observed.

1. Visual inspection
Z
Inspect vessel for damage, corrosion, etc.
In the event of damage, complete repairs or replace and determine the possible cause.
Z
Match vessel suitability to on-site use.

2. Check bladder
Briefly activate the gas filling valve. If water leaks out:
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For vessels which do not have a facility for replacing the bladder, replace
the expansion vessel.
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for vessels which have a facility for replacing the bladder,replace the bladder
or alternatively contact Reflex Service for further advice.

3. Setting gas supply pressure

Isolate the Reflex vessel from the system using the cap valve (Flowjet) and
empty on the water side.
Measure supply pressure p₀ at the gas filling valve and if necessary reset to
the required minimum operating pressure for the system.

p0 [bar] = pa – 0,2 bar*

* At greater distances (pressure loss) to the pressure reducer, increase the difference to pa to up to 1 bar.

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If the pressure is too high, blow off the gas with the gas filling valve.
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If the pressure is too low, refill with nitrogen from a pressurised container.
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Enter the reset or corrected supply pressure p0 on the type plate.

4. Functional inspection during operation

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Close drain at the cap valve and carefully open cap valve (Flowjet).
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Checking gas pressure during operation the gas pressure must now be the same as
the system pressure (compare with pressure gauge on the pressure reducer) then
the vessel is operational.
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If the vessel has heated up, the pressure in the vessel may be approximately 0.5 bar
less than the safety valve actuating pressure.

5. Gas filling valve leak test

Remove optional aids for filling and measuring at the gas filling valve and inspect
with leak test spray to see whether the gas filling valve leaks after use. Finally, refit
the cap valve, which provides the seal, on the gas filling valve.
→ The Refix expansion vessel is now ready to be used again.

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